Method and Apparatus for Assembling Disposable Absorbent Articles with an Embossed Topsheet

ABSTRACT

Aspects of the methods herein relate to the fabrication of absorbent articles wherein a continuous topsheet web is advanced in a machine direction. A liquid acquisition layer and an absorbent core are combined with the continuous topsheet web. The combined continuous topsheet web, liquid acquisition layer, and absorbent core advance through the embossing nip to emboss a pattern in the continuous topsheet web. As the combined continuous topsheet web, liquid acquisition layer, and absorbent core advance through the embossing nip, the rotating patterned embossing roll contacts the continuous topsheet web. And the rotating anvil roll contacts the absorbent core. By advancing the topsheet together with the acquisition layer and absorbent core through the embossing nip, a relatively deep pattern can be embossed into the topsheet than otherwise might be possible when embossing relatively thin topsheet web materials.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing disposableabsorbent articles having a topsheet, backsheet, acquisition layer, andabsorbent core, and more particularly, to methods for embossing atopsheet web while combined with an acquisition layer and absorbentcore.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from advancing web or webs are combinedwith other individual components created from other advancing web orwebs. Webs of material and component parts used to manufacture diapersmay include: backsheets, topsheets, leg cuffs, waist bands, acquisitionlayers, absorbent core components, front and/or back ears, fasteningcomponents, and various types of elastic webs and components such as legelastics, barrier leg cuff elastics, stretch side panels, and waistelastics. Once the desired component parts are assembled, the advancingweb(s) and component parts are subjected to a final knife cut toseparate the web(s) into discrete diapers or other absorbent articles.

The topsheets and/or backsheets of absorbent articles are sometimesconstructed from nonwoven webs, plastic films, and/or laminates thereof.In addition, the topsheets and backsheets of such absorbent articles mayfunction to absorb and/or contain the discharged materials and also toisolate bodily exudates from the wearer's skin and from the wearer'sgarments and bed clothing. In some instances, these substrates aresubstantially smooth, flat and aesthetically unappealing. Efforts havebeen made to modify these substrates in order to provide them with aparticular appearance. For example, such substrates may be modified toexhibit a softer, quilted, and/or cloth-like appearance. In someexamples, these substrates may be modified to include an interior designsignal to communicate to a caregiver that a relatively thin absorbentarticle provides adequate absorbency. As such, nonwoven fabrics and/orplastic films are sometimes modified to provide a physical or actualthree-dimensional pattern. Non-limiting examples of known methods whichprovide an actual three-dimensional appearance to a substrate includeembossing. In some configurations, the topsheet is embossed before beingcombined with other components. However, it may be difficult to emboss arelatively deep pattern and/or impart a very definitivethree-dimensional pattern into relatively thin topsheet material.Improved methods for topsheet embossing during absorbent articleassembly may be desirable.

SUMMARY OF THE INVENTION

The present disclosure relates to methods for making absorbent articleswith embossed topsheets. Aspects of the methods discussed herein relateto the fabrication of absorbent articles wherein a continuous topsheetweb having a first surface and an opposing second surface is advanced ina machine direction. A liquid acquisition layer and an absorbent coreare combined with the continuous topsheet web. The combined continuoustopsheet web, liquid acquisition layer, and absorbent core through theembossing nip to emboss a pattern in the continuous topsheet web. Theembossing nip may be defined between a rotating patterned embossing rolland a rotating anvil roll. As the combined continuous topsheet web,liquid acquisition layer, and absorbent core advance through theembossing nip, the rotating patterned embossing roll contacts thecontinuous topsheet web. And the rotating anvil roll contacts theabsorbent core. By advancing the topsheet together with the acquisitionlayer and absorbent core through the embossing nip, a relatively deeppattern can be embossed into the topsheet than otherwise might bepossible when embossing relatively thin topsheet web materials.

In one form, a process may be adapted for assembling disposableabsorbent articles, wherein each absorbent article includes a chassishaving a first waist region longitudinally opposed to a second waistregion, and having a longitudinal axis and a lateral axis, the chassiscomprising: a topsheet, a backsheet, and a liquid acquisition layer anda substantially cellulose free absorbent core disposed between thetopsheet and the backsheet. The process may include the steps of:advancing a continuous topsheet web having a first surface and anopposing second surface in a machine direction; combining a liquidacquisition layer with the continuous topsheet web, wherein the liquidacquisition layer includes a first surface and an opposing secondsurface, and wherein the first surface of the liquid acquisition layeris positioned in a facing relationship with the second surface of thecontinuous topsheet web; combining an absorbent core with the liquidacquisition layer, wherein the absorbent core includes a first surfaceand an opposing second surface, and wherein the first surface of theabsorbent core is positioned in a facing relationship with the secondsurface of the liquid acquisition layer; providing an embossing nipbetween a rotating patterned embossing roll and a rotating anvil roll;and embossing a pattern in the continuous topsheet web by advancing thecombined continuous topsheet web, liquid acquisition layer, andabsorbent core through the embossing nip, wherein the rotating patternedembossing roll contacts the first surface of the continuous topsheetweb, and wherein the rotating anvil roll contacts the second surface ofthe absorbent core.

In another form, a process may be adapted for assembling disposableabsorbent articles, wherein each absorbent article comprising a chassishaving a first waist region longitudinally opposed to a second waistregion, and having a longitudinal axis and a lateral axis, the chassiscomprising: a topsheet, a backsheet, and a liquid acquisition layer anda substantially cellulose free absorbent core disposed between thetopsheet and the backsheet. The process may include the steps of:advancing a continuous topsheet web having a first surface and anopposing second surface in a machine direction; combining a liquidacquisition layer with the continuous topsheet web, wherein the liquidacquisition layer includes a first surface and an opposing secondsurface, and wherein the first surface of the liquid acquisition layeris positioned in a facing relationship with the second surface of thecontinuous topsheet web; combining an absorbent core with the liquidacquisition layer, wherein the absorbent core includes a first surfaceand an opposing second surface, and wherein the first surface of theabsorbent core is positioned in a facing relationship with the secondsurface of the liquid acquisition layer; providing an embossing nipbetween a rotating embossing roll and a rotating anvil roll, theembossing roll comprising an embossing element; and creating indentedregions in the continuous topsheet web by advancing the combinedcontinuous topsheet web, liquid acquisition layer, and absorbent corethrough the embossing nip, wherein the embossing element contacts thefirst surface of the continuous topsheet web, and wherein the rotatinganvil roll contacts the second surface of the absorbent core.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a diaper.

FIG. 2 is a cross sectional view of the diaper shown in FIG. 1 takenalong the sectional line 2-2 of FIG. 1.

FIG. 3 is a partial cross sectional view of an absorbent core layer.

FIG. 4 is a partial cross sectional view of an absorbent core layer.

FIG. 5 is a plan view of the absorbent core layer illustrated in FIG. 3.

FIG. 6 is a plan view of a second absorbent core layer.

FIG. 7 a is a partial sectional view of an absorbent core comprising acombination of the first and second absorbent core layers illustrated inFIGS. 5 and 6.

FIG. 7 b is a partial sectional view of an absorbent core comprising acombination of the first and second absorbent core layers illustrated inFIGS. 5 and 6.

FIG. 8 is a plan view of the absorbent core illustrated in FIGS. 7 a and7 b.

FIG. 9 is a schematic illustration of a process for making an absorbentcore.

FIG. 10 is a partial sectional view of an apparatus for making anabsorbent core.

FIG. 11 is a perspective view of the printing roll illustrated in FIG.10.

FIG. 12 is a partial sectional view of the printing roll illustrated inFIG. 11 showing an absorbent particulate polymer material reservoir.

FIG. 13 is a perspective view of the supporting roll illustrated in FIG.11.

FIG. 14 is a schematic side view an apparatus for assembling componentsof an absorbent article and embossing a topsheet web.

FIG. 15 is a detailed cross-sectional view of a topsheet web,acquisition layer, and absorbent core advancing through an embossingnip.

FIG. 16 is a plan view of a topsheet web including a pattern of discreteembossments, such as taken along line 16-16 in FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” refers to devices that absorb and contain bodyexudates, and, more specifically, refers to devices that are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Absorbent articles mayinclude diapers, training pants, adult incontinence undergarments,feminine hygiene products, breast pads, care mats, bibs, wound dressingproducts, and the like. As used herein, the term “body fluids” or “bodyexudates” includes, but is not limited to, urine, blood, vaginaldischarges, breast milk, sweat and fecal matter.

“Absorbent core” means a structure that may be disposed between atopsheet and backsheet of an absorbent article for absorbing andcontaining liquid received by the absorbent article and may comprise oneor more substrates, absorbent polymer material disposed on the one ormore substrates, and a thermoplastic composition on the absorbentparticulate polymer material and at least a portion of the one or moresubstrates for immobilizing the absorbent particulate polymer materialon the one or more substrates. In a multilayer absorbent core, theabsorbent core may also include a cover layer. The one or moresubstrates and the cover layer may comprise a nonwoven. Further, theabsorbent core is substantially cellulose free. The absorbent core doesnot include an acquisition system, a topsheet, or a backsheet of theabsorbent article. In a certain embodiment, the absorbent core wouldconsist essentially of the one or more substrates, the absorbent polymermaterial, the thermoplastic composition, and optionally the cover layer.

“Absorbent polymer material,” “absorbent gelling material,” “AGM,”“superabsorbent,” and “superabsorbent material” are used hereininterchangeably and refer to cross linked polymeric materials that canabsorb at least 5 times their weight of an aqueous 0.9% saline solutionas measured using the Centrifuge Retention Capacity test (Edana441.2-01).

“Absorbent particulate polymer material” is used herein to refer to anabsorbent polymer material which is in particulate form so as to beflowable in the dry state.

“Absorbent particulate polymer material area” as used herein refers tothe area of the core wherein the first substrate 64 and second substrate72 are separated by a multiplicity of superabsorbent particles. In FIG.8, the boundary of the absorbent particulate polymer material area isdefined by the perimeter of the overlapping circles. There may be someextraneous superabsorbent particles outside of this perimeter betweenthe first substrate 64 and second substrate 72.

“Airfelt” is used herein to refer to comminuted wood pulp, which is aform of cellulosic fiber.

The term “body facing surface” and “body facing side” refer to surfacesof absorbent articles and/or components thereof which face a wearer'sbody when the absorbent articles are worn, and the term “garment facingsurface” and “garment facing side” refer to surfaces of absorbentarticles and/or components thereof that face away from a wearer's bodywhen the absorbent articles are worn. Absorbent articles and componentsthereof, including the topsheet, backsheet, absorbent core, and anyindividual materials of their components, have a body facing surfaceand/or side and a garment facing surface and/or side.

“Comprise,” “comprising,” and “comprises” are open ended terms, eachspecifies the presence of what follows, e.g., a component, but does notpreclude the presence of other features, e.g., elements, steps,components known in the art, or disclosed herein.

“Consisting essentially of” is used herein to limit the scope of subjectmatter, such as that in a claim, to the specified materials or steps andthose that do not materially affect the basic and novel characteristicsof the subject matter.

“Disposable” is used in its ordinary sense to mean an article that isdisposed or discarded after a limited number of usage events overvarying lengths of time, for example, less than about 20 events, lessthan about 10 events, less than about 5 events, or less than about 2events.

“Diaper” refers to an absorbent article generally worn by infants andincontinent persons about the lower torso so as to encircle the waistand legs of the wearer and that is specifically adapted to receive andcontain urinary and fecal waste. As used herein, term “diaper” alsoincludes a “pant” which is defined below.

“Fiber” and “filament” are used interchangeably.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process. The term “cross direction” (CD) is usedherein to refer to a direction that is generally perpendicular to themachine direction.

A “nonwoven” is a manufactured sheet, web or batt of directionally orrandomly orientated fibers, bonded by friction, and/or cohesion and/oradhesion, excluding paper and products which are woven, knitted, tufted,stitch-bonded incorporating binding yarns or filaments, or felted bywet-milling, whether or not additionally needled. The fibers may be ofnatural or man-made origin and may be staple or continuous filaments orbe formed in situ. Commercially available fibers have diameters rangingfrom less than about 0.001 mm to more than about 0.2 mm and they come inseveral different forms: short fibers (known as staple, or chopped),continuous single fibers (filaments or monofilaments), untwisted bundlesof continuous filaments (tow), and twisted bundles of continuousfilaments (yarn). Nonwoven fabrics can be formed by many processes suchas meltblowing, spunbonding, solvent spinning, electrospinning, andcarding. The basis weight of nonwoven fabrics is usually expressed ingrams per square meter (gsm).

“Pant” or “training pant”, as used herein, refer to disposable garmentshaving a waist opening and leg openings designed for infant or adultwearers. A pant may be placed in position on the wearer by inserting thewearer's legs into the leg openings and sliding the pant into positionabout a wearer's lower torso. A pant may be preformed by any suitabletechnique including, but not limited to, joining together portions ofthe article using refastenable and/or non-refastenable bonds (e.g.,seam, weld, adhesive, cohesive bond, fastener, etc.). A pant may bepreformed anywhere along the circumference of the article (e.g., sidefastened, front waist fastened). While the terms “pant” or “pants” areused herein, pants are also commonly referred to as “closed diapers,”“prefastened diapers,” “pull-on diapers,” “training pants,” and“diaper-pants”. Suitable pants are disclosed in U.S. Pat. No. 5,246,433,issued to Hasse, et al. on Sep. 21, 1993; U.S. Pat. No. 5,569,234,issued to Buell et al. on Oct. 29, 1996; U.S. Pat. No. 6,120,487, issuedto Ashton on Sep. 19, 2000; U.S. Pat. No. 6,120,489, issued to Johnsonet al. on Sep. 19, 2000; U.S. Pat. No. 4,940,464, issued to Van Gompelet al. on Jul. 10, 1990; U.S. Pat. No. 5,092,861, issued to Nomura etal. on Mar. 3, 1992; U.S. Patent Publication No. 2003/0233082 A1,entitled “Highly Flexible And Low Deformation Fastening Device”, filedon Jun. 13, 2002; U.S. Pat. No. 5,897,545, issued to Kline et al. onApr. 27, 1999; U.S. Pat. No. 5,957,908, issued to Kline et al on Sep.28, 1999.

“Substantially cellulose free” is used herein to describe an article,such as an absorbent core, that contains less than 10% by weightcellulosic fibers, less than 5% cellulosic fibers, less than 1%cellulosic fibers, no cellulosic fibers, or no more than an immaterialamount of cellulosic fibers. An immaterial amount of cellulosic materialwould not materially affect the thinness, flexibility, or absorbency ofan absorbent core.

“Substantially continuously distributed” as used herein indicates thatwithin the absorbent particulate polymer material area, the firstsubstrate 64 and second substrate 72 are separated by a multiplicity ofsuperabsorbent particles. It is recognized that there may be minorincidental contact areas between the first substrate 64 and secondsubstrate 72 within the absorbent particulate polymer material area.Incidental contact areas between the first substrate 64 and secondsubstrate 72 may be intentional or unintentional (e.g. manufacturingartifacts) but do not form geometries such as pillows, pockets, tubes,quilted patterns and the like.

“Thermoplastic adhesive material” as used herein is understood tocomprise a polymer composition from which fibers are formed and appliedto the superabsorbent material with the intent to immobilize thesuperabsorbent material in both the dry and wet state. The thermoplasticadhesive material of the present disclosure forms a fibrous network overthe superabsorbent material.

“Thickness” and “caliper” are used herein interchangeably.

The present disclosure relates to methods for manufacturing absorbentarticles, and in particular, methods for making absorbent articles withembossed topsheets. As discussed in more detail below, absorbentarticles, such as diapers may include a chassis having a first waistregion longitudinally opposed to a second waist region, and having alongitudinal axis and a lateral axis, the chassis comprising: atopsheet, a backsheet, and a liquid acquisition layer and asubstantially cellulose free absorbent core disposed between thetopsheet and the backsheet. Aspects of the methods according to thepresent disclosure relate to the fabrication of absorbent articleswherein a continuous topsheet web having a first surface and an opposingsecond surface is advanced in a machine direction. A liquid acquisitionlayer and an absorbent core are combined with the continuous topsheetweb. The combined continuous topsheet web, liquid acquisition layer, andabsorbent core advance through the embossing nip to emboss a pattern inthe continuous topsheet web. As discussed in more detail below, theembossing nip may be defined between a rotating patterned embossing rolland a rotating anvil roll. As the combined continuous topsheet web,liquid acquisition layer, and absorbent core advance through theembossing nip, the rotating patterned embossing roll contacts thecontinuous topsheet web. And the rotating anvil roll contacts the secondsurface of the absorbent core. By advancing the topsheet together withthe acquisition layer and absorbent core through the embossing nip, arelatively deeper pattern can be embossed into the topsheet thanotherwise might be possible when embossing relatively thin topsheet webmaterials.

The following provides a general description of various types ofabsorbent articles that may be produced with the methods and apparatusesdisclosed herein to help provide additional context to the subsequentdiscussion of the process embodiments.

FIG. 1 is a plan view of a diaper 10 is shown in a flat out,uncontracted state (i.e., without elastic induced contraction) and withportions of the diaper 10 are cut away to more clearly show theunderlying structure of the diaper 10. A portion of the diaper 10 thatcontacts a wearer is facing the viewer in FIG. 1. The diaper 10generally may include a chassis 12 and an absorbent core 14 disposed inthe chassis.

The chassis 12 of the diaper 10 in FIG. 1 may include an outer covering16 including a topsheet 18, which may be liquid pervious, and/or abacksheet 20, which may be liquid impervious. The absorbent core 14 maybe encased between the topsheet 18 and the backsheet 20. The chassis 12may also include side panels 22, elasticized leg cuffs 24, and anelastic waist feature 26.

The leg cuffs 24 and the elastic waist feature 26 may each includeelastic members 28. One end portion of the diaper 10 may be configuredas a first waist region 30 of the diaper 10. An opposite end portion ofthe diaper 10 may be configured as a second waist region 32 of thediaper 10. An intermediate portion of the diaper 10 may be configured asa crotch region 34, which extends longitudinally between the first andsecond waist regions 30 and 32. The waist regions 30 and 32 may includeelastic elements such that they gather about the waist of the wearer toprovide improved fit and containment (elastic waist feature 26). Thecrotch region 34 is that portion of the diaper 10 which, when the diaper10 is worn, is generally positioned between the wearer's legs.

The diaper 10 is depicted in FIG. 1 with a longitudinal axis 36 and atransverse axis 38. The periphery 40 of the diaper 10 is defined by theouter edges of the diaper 10 in which the longitudinal edges 42 rungenerally parallel to the longitudinal axis 36 of the diaper 10 and theend edges 44 run between the longitudinal edges 42 generally parallel tothe transverse axis 38 of the diaper 10. The chassis 12 may alsocomprise a fastening system, which may include at least one fasteningmember 46 and at least one stored landing zone 48.

The diaper 20 may also include such other features as are known in theart including front and rear ear panels, waist cap features, elasticsand the like to provide better fit, as well as containment and aestheticcharacteristics. Such additional features are described, for example, inU.S. Pat. Nos. 3,860,003 and 5,151,092.

In order to keep the diaper 10 in place about the wearer, at least aportion of the first waist region 30 may be attached by the fasteningmember 46 to at least a portion of the second waist region 32 to formleg opening(s) and an article waist opening. When fastened, thefastening system carries a tensile load around the article waist. Thefastening system may allow an article user to hold one element of thefastening system, such as the fastening member 46, and connect the firstwaist region 30 to the second waist region 32 in at least two places.This may be achieved through manipulation of bond strengths between thefastening device elements.

In some embodiments, the diaper 10 may be provided with a re-closablefastening system or may alternatively be provided in the form of apant-type diaper. When the absorbent article is a diaper, it may includea re-closable fastening system joined to the chassis for securing thediaper to a wearer. When the absorbent article is a pant-type diaper,the article may include at least two side panels joined to the chassisand to each other to form a pant. The fastening system and any componentthereof may include any material suitable for such a use, including butnot limited to plastics, films, foams, nonwoven, woven, paper,laminates, fiber reinforced plastics and the like, or combinationsthereof. In some embodiments, the materials making up the fasteningdevice may be flexible. The flexibility may allow the fastening systemto conform to the shape of the body and thus, reduce the likelihood thatthe fastening system will irritate or injure the wearer's skin.

It is to be appreciated that the topsheet 18, the backsheet 20, and theabsorbent core 14 may be assembled in a variety of configurations, suchas for example as described generally in U.S. Pat. Nos. 5,554,145;5,569,234; and 6,004,306.

The topsheet 18 in FIG. 1 may be fully or partially elasticized or maybe foreshortened to provide a void space between the topsheet 18 and theabsorbent core 14. Exemplary structures including elasticized orforeshortened topsheets are described in more detail in U.S. Pat. Nos.5,037,416 and 5,269,775.

The backsheet 26 may be joined with the topsheet 18. The backsheet 20may prevent the exudates absorbed by the absorbent core 14 and containedwithin the diaper 10 from soiling other external articles that maycontact the diaper 10, such as bed sheets and undergarments. In certainembodiments, the backsheet 26 may be substantially impervious to liquids(e.g., urine) and comprise a laminate of a nonwoven and a thin plasticfilm such as a thermoplastic film having a thickness of about 0.012 mm(0.5 mil) to about 0.051 mm (2.0 mils). Suitable backsheet films includethose manufactured by Tredegar Industries Inc. of Terre Haute, Ind. andsold under the trade names X15306, X10962, and X10964. Other suitablebacksheet materials may include breathable materials that permit vaporsto escape from the diaper 10 while still preventing liquid exudates frompassing through the backsheet 10. Exemplary breathable materials mayinclude materials such as woven webs, nonwoven webs, composite materialssuch as film-coated nonwoven webs, and microporous films such asmanufactured by Mitsui Toatsu Co., of Japan under the designation ESPOIRNO and by EXXON Chemical Co., of Bay City, Tex., under the designationEXXAIRE. Suitable breathable composite materials comprising polymerblends are available from Clopay Corporation, Cincinnati, Ohio under thename HYTREL blend P18-3097. Such breathable composite materials aredescribed in greater detail in PCT Application No. WO 95/16746,published on Jun. 22, 1995 in the name of E. I. DuPont. Other breathablebacksheets including nonwoven webs and apertured formed films aredescribed in U.S. Pat. No. 5,571,096.

FIG. 2 is a cross sectional view of the diaper in FIG. 1 taken along theline 2-2. As shown in FIG. 2, the topsheet 18 may define an inner, bodyfacing surface, and the backsheet may define an outer, garment facingsurface of the diaper 10. And the absorbent core 14 may be positionedbetween the topsheet and the backsheet. The diaper 10 may also includean acquisition system 50 disposed between the liquid permeable topsheet18 and a wearer facing side of the absorbent core 14. The acquisitionsystem 50 may be in direct contact with the absorbent core. Theacquisition system 50 (also referred to herein as a liquid acquisitionlayer 50) may comprise a single layer or multiple layers, such as anupper acquisition layer 52 (also referred to herein as a firstacquisition layer 52) facing towards the wearer's skin and a loweracquisition layer 54 (also referred to herein as a second acquisitionlayer 54) facing the garment of the wearer. According to a certainembodiment, the acquisition system 50 may function to receive a surge ofliquid, such as a gush of urine. In other words, the acquisition system50 may serve as a temporary reservoir for liquid until the absorbentcore 14 can absorb the liquid.

In some embodiments, the acquisition system 50 may include chemicallycross-linked cellulosic fibers. Such cross-linked cellulosic fibers mayhave desirable absorbency properties. Exemplary chemically cross-linkedcellulosic fibers are disclosed in U.S. Pat. No. 5,137,537. In certainembodiments, the chemically cross-linked cellulosic fibers arecross-linked with between about 0.5 mole % and about 10.0 mole % of a C₂to C₉ polycarboxylic cross-linking agent or between about 1.5 mole % andabout 6.0 mole % of a C₂ to C₉ polycarboxylic cross-linking agent basedon glucose unit. Citric acid is an exemplary cross-linking agent. Insome embodiments, polyacrylic acids may be used. Further, according tosome embodiments, the cross-linked cellulosic fibers have a waterretention value of about 25 to about 60, or about 28 to about 50, orabout 30 to about 45. A method for determining water retention value isdisclosed in U.S. Pat. No. 5,137,537. In some embodiments, thecross-linked cellulosic fibers may be crimped, twisted, or curled, or acombination thereof including crimped, twisted, and curled.

In some embodiments, one or both of the upper acquisition layer 52 andlower acquisition layer 54 may include a nonwoven, which may behydrophilic. Further, according to some embodiments, one or both of theupper acquisition layer 52 and lower acquisition layer 54 may comprisethe chemically cross-linked cellulosic fibers, which may or may not formpart of a nonwoven material. In some embodiments, the upper acquisitionlayer 52 may comprise a nonwoven, without the cross-linked cellulosicfibers, and the lower acquisition layer 54 may comprise the chemicallycross-linked cellulosic fibers. Further, in some embodiments, the loweracquisition layer 54 may comprise the chemically cross-linked cellulosicfibers mixed with other fibers such as natural or synthetic polymericfibers. According to some embodiments, such other natural or syntheticpolymeric fibers may include high surface area fibers, thermoplasticbinding fibers, polyethylene fibers, polypropylene fibers, PET fibers,rayon fibers, lyocell fibers, and mixtures thereof. In some embodiments,the lower acquisition layer 54 has a total dry weight, the cross-linkedcellulosic fibers are present on a dry weight basis in the upperacquisition layer in an amount from about 30% to about 95% by weight ofthe lower acquisition layer 54, and the other natural or syntheticpolymeric fibers are present on a dry weight basis in the loweracquisition layer 54 in an amount from about 70% to about 5% by weightof the lower acquisition layer 54. According to some embodiments, thecross-linked cellulosic fibers are present on a dry weight basis in thefirst acquisition layer in an amount from about 80% to about 90% byweight of the lower acquisition layer 54, and the other natural orsynthetic polymeric fibers are present on a dry weight basis in thelower acquisition layer 54 in an amount from about 20% to about 10% byweight of the lower acquisition layer 54.

For example, in some embodiments, the lower acquisition layer 54 maycomprise about 70% by weight of chemically cross-linked cellulosefibers, about 10% by weight polyester (PET), and about 20% by weightuntreated pulp fibers. According to a second embodiment, the loweracquisition layer 54 may comprise about 70% by weight chemicallycross-linked cellulose fibers, about 20% by weight lyocell fibers, andabout 10% by weight PET fibers. According to a third embodiment, thelower acquisition layer 54 may comprise about 68% by weight chemicallycross-linked cellulose fibers, about 16% by weight untreated pulpfibers, and about 16% by weight PET fibers. In one embodiment, the loweracquisition layer 54 may comprise from about 90-100% by weightchemically cross-linked cellulose fibers.

Suitable nonwoven materials for the upper acquisition layer 52 and loweracquisition layer 54 include, but are not limited to SMS material,comprising a spunbonded, a melt-blown and a further spunbonded layer. Incertain embodiments, permanently hydrophilic nonwovens, and inparticular, nonwovens with durably hydrophilic coatings are desirable.Another suitable embodiment comprises a SMMS-structure. In certainembodiments, the nonwovens are porous.

In certain embodiments, suitable nonwoven materials may include, but arenot limited to synthetic fibers, such as PE, PET, and PP. As polymersused for nonwoven production may be inherently hydrophobic, they may becoated with hydrophilic coatings. One way to produce nonwovens withdurably hydrophilic coatings, is via applying a hydrophilic monomer anda radical polymerization initiator onto the nonwoven, and conducting apolymerization activated via UV light resulting in monomer chemicallybound to the surface of the nonwoven as described in co-pending U.S.Patent Publication No. 2005/0159720. Another way to produce nonwovenswith durably hydrophilic coatings is to coat the nonwoven withhydrophilic nanoparticles as described in U.S. Pat. No. 7,112,621 and inPCT Publication No. WO 02/064877.

Nanoparticles may have a largest dimension of below 750 nm.Nanoparticles with sizes ranging from 2 to 750 nm may be economicallyproduced. Some nanoparticles can be easily dispersed in water solutionto enable coating application onto the nonwoven, form transparentcoatings, and the coatings applied from water solutions are may besufficiently durable to exposure to water. Nanoparticles can be organicor inorganic, synthetic or natural. Inorganic nanoparticles generallyexist as oxides, silicates, and/or, carbonates. Typical examples ofsuitable nanoparticles are layered clay minerals (e.g., LAPONITE™ fromSouthern Clay Products, Inc. (USA), and Boehmite alumina (e.g., DisperalP2™ from North American Sasol. Inc.). According to a certain embodiment,a suitable nanoparticle coated nonwoven is that disclosed in the U.S.Patent Publication No. 20040158212A1.

Other nonwovens are described in U.S. Patent Nos. 6,645,569; 6,863,933;and 7,112,621 as well as U.S. Patent Publication Nos. 20030148684A1 and20050008839A1.

In some cases, the nonwoven surface can be pre-treated with high energytreatment (corona, plasma) prior to application of nanoparticlecoatings. High energy pre-treatment typically temporarily increases thesurface energy of a low surface energy surface (such as PP) and thusenables better wetting of a nonwoven by the nanoparticle dispersion inwater.

Notably, permanently hydrophilic nonwovens may be used in other parts ofan absorbent article. For example, topsheets and absorbent core layerscomprising permanently hydrophilic nonwovens as described above can beused.

According to some embodiments, the upper acquisition layer 52 mayinclude a material that provides recovery when external pressure isapplied and removed. Further, according to some embodiments, the upperacquisition layer 52 may comprise a blend of different fibers selected,for example from the types of polymeric fibers described above. In someembodiments, at least a portion of the fibers may exhibit a spiral-crimpwhich has a helical shape. In some embodiments, the upper acquisitionlayer 52 may comprise fibers having different degrees or types ofcrimping, or both. For example, embodiments may include a mixture offibers having about 8 to about 12 crimps per inch (cpi) or about 9 toabout 10 cpi, and other fibers having about 4 to about 8 cpi or about 5to about 7 cpi. Different types of crimps include, but are not limitedto a 2D crimp or “flat crimp” and a 3D or spiral-crimp. According tosome embodiments, the fibers may include bi-component fibers, which areindividual fibers each comprising different materials, usually a firstand a second polymeric material.

The upper acquisition layer 52 may be stabilized by a latex binder, forexample a styrene-butadiene latex binder (SB latex), in a certainembodiment. Processes for obtaining such lattices are known, forexample, from EP Patent Publication No. EP0149880A2 and U.S. PatentPublication No. 20030105190. In some embodiments, the binder may bepresent in the upper acquisition layer 52 in excess of about 12%, about14% or about 16% by weight. For certain embodiments, SB latex isavailable under the trade name GENFLO™ 3160 (OMNOVA Solutions Inc.;Akron, Ohio).

The absorbent core 14, such as shown in FIGS. 1-8 may be disposedbetween the topsheet 18 and the backsheet 20 and may include two layers,a first absorbent layer 60 and a second absorbent layer 62. As shown inFIG. 3, the first absorbent layer 60 of the absorbent core 14 mayinclude a substrate 64, an absorbent particular polymer material 66 onthe substrate 64, and a thermoplastic composition 68 on the absorbentparticulate polymer material 66 and at least portions of the firstsubstrate 64 as an adhesive for covering and immobilizing the absorbentparticulate polymer material 66 on the first substrate 64. According toanother embodiment illustrated in FIG. 4, the first absorbent layer 60of the absorbent core 14 may also include a cover layer 70 on thethermoplastic composition 68.

As shown in FIG. 2, the second absorbent layer 62 of the absorbent core14 may also include a substrate 72, an absorbent particulate polymermaterial 74 on the second substrate 72, and a thermoplastic composition66 on the absorbent particulate polymer material 74 and at least aportion of the second substrate 72 for immobilizing the absorbentparticulate polymer material 74 on the second substrate 72. Although notillustrated, the second absorbent layer 62 may also include a coverlayer such as the cover layer 70 illustrated in FIG. 4.

The substrate 64 of the first absorbent layer 60 may be referred to as adusting layer and has a first surface 78 which faces the backsheet 20 ofthe diaper 10 and a second surface 80 which faces the absorbentparticulate polymer material 66. The substrate 72 of the secondabsorbent layer 62 may be referred to as a core cover and has a firstsurface 82 facing the topsheet 18 of the diaper 10 and a second surface84 facing the absorbent particulate polymer material 74. The first andsecond substrates 64 and 72 may be adhered to one another with adhesiveabout the periphery to form an envelope about the absorbent particulatepolymer materials 66 and 74 to hold the absorbent particulate polymermaterial 66 and 74 within the absorbent core 14.

In some embodiments, the substrates 64 and 72 of the first and secondabsorbent layers 60 and 62 may be a nonwoven material, such as thosenonwoven materials described above. In some embodiments, the nonwovensare porous and may have a pore size of about 32 microns.

As shown in FIGS. 1-8, the absorbent particulate polymer material 66 and74 is deposited on the respective substrates 64 and 72 of the first andsecond absorbent layers 60 and 62 in clusters 90 of particles to form agrid pattern 92 comprising land areas 94 and junction areas 96 betweenthe land areas 94. As defined herein, land areas 94 are areas where thethermoplastic adhesive material does not contact the nonwoven substrateor the auxiliary adhesive directly; junction areas 96 are areas wherethe thermoplastic adhesive material does contact the nonwoven substrateor the auxiliary adhesive directly. The junction areas 96 in the gridpattern 92 contain little or no absorbent particulate polymer material66 and 74. The land areas 94 and junction areas 96 can have a variety ofshapes including, but not limited to, circular, oval, square,rectangular, triangular, and the like.

The grid pattern shown in FIG. 8 is a square grid with regular spacingand size of the land areas. Other grid patterns including hexagonal,rhombic, orthorhombic, parallelogram, triangular, rectangular, andcombinations thereof may also be used. The spacing between the gridlines may be regular or irregular.

The size of the land areas 94 in the grid patterns 92 may vary.According to certain embodiments, the width 119 of the land areas 94 inthe grid patterns 92 ranges from about 8 mm to about 12 mm. In a certainembodiment, the width of the land areas 94 is about 10 mm. The junctionareas 96, on the other hand, in certain embodiments, have a width orlarger span of less than about 5 mm, less than about 3 mm, less thanabout 2 mm, less than about 1.5 mm, less than about 1 mm, or less thanabout 0.5 mm.

As shown in FIG. 8, the absorbent core 14 has a longitudinal axis 100extending from a rear end 102 to a front end 104 and a transverse axis106 perpendicular to the longitudinal axis 100 extending from a firstedge 108 to a second edge 110. The grid pattern 92 of absorbentparticulate polymer material clusters 90 is arranged on the substrates64 and 72 of the respective absorbent layers 60 and 62 such that thegrid pattern 92 formed by the arrangement of land areas 94 and junctionareas 96 forms a pattern angle 112. The pattern angle 112 may be 0,greater than 0, or 15 to 30 degrees, or from about 5 to about 85degrees, or from about 10 to about 60 degrees, or from about 15 to about30 degrees.

As shown in FIGS. 7 a, 7 b, and 8, the first and second layers 60 and 62may be combined to form the absorbent core 14. The absorbent core 14 hasan absorbent particulate polymer material area 114 bounded by a patternlength 116 and a pattern width 118. The extent and shape of theabsorbent particulate polymer material area 114 may vary depending onthe desired application of the absorbent core 14 and the particularabsorbent article in which it may be incorporated. In some embodiments,the absorbent particulate polymer material area 114 extendssubstantially entirely across the absorbent core 14, such as isillustrated in FIG. 8.

The first and second absorbent layers 60 and 62 may be combined togetherto form the absorbent core 14 such that the grid patterns 92 of therespective first and second absorbent layers 62 and 64 are offset fromone another along the length and/or width of the absorbent core 14. Therespective grid patterns 92 may be offset such that the absorbentparticulate polymer material 66 and 74 is substantially continuouslydistributed across the absorbent particulate polymer area 114. In acertain embodiment, absorbent particulate polymer material 66 and 74 issubstantially continuously distributed across the absorbent particulatepolymer material area 114 despite the individual grid patterns 92comprising absorbent particulate polymer material 66 and 74discontinuously distributed across the first and second substrates 64and 72 in clusters 90. In some embodiments, the grid patterns may beoffset such that the land areas 94 of the first absorbent layer 60 facethe junction areas 96 of the second absorbent layer 62 and the landareas of the second absorbent layer 62 face the junction areas 96 of thefirst absorbent layer 60. When the land areas 94 and junction areas 96are appropriately sized and arranged, the resulting combination ofabsorbent particulate polymer material 66 and 74 is a substantiallycontinuous layer of absorbent particular polymer material across theabsorbent particulate polymer material area 114 of the absorbent core 14(i.e. first and second substrates 64 and 72 do not form a plurality ofpockets, each containing a cluster 90 of absorbent particulate polymermaterial 66 therebetween). In a certain embodiment, respective gridpatterns 92 of the first and second absorbent layer 60 and 62 may besubstantially the same.

In some embodiments, such as shown in FIG. 8, the amount of absorbentparticulate polymer material 66 and 74 may vary along the length 116 ofthe grid pattern 92. The grid pattern may be divided into absorbentzones 120, 122, 124, and 126, in which the amount of absorbentparticulate polymer material 66 and 74 varies from zone to zone. As usedherein, “absorbent zone” refers to a region of the absorbent particulatepolymer material area having boundaries that are perpendicular to thelongitudinal axis shown in FIG. 8. The amount of absorbent particulatepolymer material 66 and 74 may, in a certain embodiment, graduallytransition from one of the plurality of absorbent zones 120, 122, 124,and 126 to another.

The amount of absorbent particulate polymer material 66 and 74 presentin the absorbent core 14 may vary, but in certain embodiments, ispresent in the absorbent core in an amount greater than about 80% byweight of the absorbent core, or greater than about 85% by weight of theabsorbent core, or greater than about 90% by weight of the absorbentcore, or greater than about 95% by weight of the core. In someembodiments, the absorbent core 14 consists essentially of the first andsecond substrates 64 and 72, the absorbent particulate polymer material66 and 74, and the thermoplastic adhesive composition 68 and 76. In someembodiments, the absorbent core 14 may be substantially cellulose free.

In some embodiments, the weight of absorbent particulate polymermaterial 66 and 74 in at least one freely selected first squaremeasuring 1 cm×1 cm may be at least about 10%, or 20%, or 30%, 40% or50% higher than the weight of absorbent particulate polymer material 66and 74 in at least one freely selected second square measuring 1 cm×1cm. In a some embodiments, the first and the second square are centeredabout the longitudinal axis.

The absorbent particulate polymer material area may have a relativelynarrow width in the crotch area of the absorbent article for increasedwearing comfort. Hence, the absorbent particulate polymer material areamay have a width as measured along a transverse line which is positionedat equal distance to the front edge and the rear edge of the absorbentarticle, which is less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm oreven less than about 50 mm.

It some absorbent articles, such as diapers, liquid discharge from thewearer may occur predominately in the front half of the diaper. Thefront half of the absorbent core 14 may therefore comprise most of theabsorbent capacity of the core. Thus, according to certain embodiments,the front half of said absorbent core 14 may comprise more than about60% of the superabsorbent material, or more than about 65%, 70%, 75%,80%, 85%, or 90% of the superabsorbent material.

In certain embodiments, the absorbent core 14 may further comprise anyabsorbent material that is generally compressible, conformable,non-irritating to the wearer's skin, and capable of absorbing andretaining liquids such as urine and other certain body exudates. In suchembodiments, the absorbent core 14 may comprise a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp, which is generallyreferred to as airfelt, creped cellulose wadding, melt blown polymers,including co-form, chemically stiffened, modified or cross-linkedcellulosic fibers, tissue, including tissue wraps and tissue laminates,absorbent foams, absorbent sponges, or any other known absorbentmaterial or combinations of materials. The absorbent core 14 may furthercomprise minor amounts (typically less than about 10%) of materials,such as adhesives, waxes, oils and the like. Exemplary absorbentstructures for use as the absorbent assemblies are described in U.S.Pat. Nos. 4,610,678; 4,834,735; 4,888,231; 5,260,345; 5,387,207;5,397,316; and 5,625,222.

The thermoplastic adhesive material 68 and 76 may serve to cover and atleast partially immobilize the absorbent particulate polymer material 66and 74. In some embodiments, the thermoplastic adhesive material 68 and76 can be disposed essentially uniformly within the absorbentparticulate polymer material 66 and 74, between the polymers. In someembodiments, the thermoplastic adhesive material 68 and 76 may beprovided as a fibrous layer which is at least partially in contact withthe absorbent particulate polymer material 66 and 74 and partially incontact with the substrate layers 64 and 72 of the first and secondabsorbent layers 60 and 62. FIGS. 3, 4, and 7 show such a structurewherein the absorbent particulate polymer material 66 and 74 is providedas a discontinuous layer, and a layer of fibrous thermoplastic adhesivematerial 68 and 76 is laid down onto the layer of absorbent particulatepolymer material 66 and 74, such that the thermoplastic adhesivematerial 68 and 76 is in direct contact with the absorbent particulatepolymer material 66 and 74, but also in direct contact with the secondsurfaces 80 and 84 of the substrates 64 and 72, where the substrates arenot covered by the absorbent particulate polymer material 66 and 74.This imparts an essentially three-dimensional structure to the fibrouslayer of thermoplastic adhesive material 68 and 76, which in itself isessentially a two-dimensional structure of relatively small thickness,as compared to the dimension in length and width directions. In otherwords, the thermoplastic adhesive material 68 and 76 undulates betweenthe absorbent particulate polymer material 68 and 76 and the secondsurfaces of the substrates 64 and 72.

Thereby, the thermoplastic adhesive material 68 and 76 may providecavities to cover the absorbent particulate polymer material 66 and 74,and thereby immobilizes this material. In a further aspect, thethermoplastic adhesive material 68 and 76 bonds to the substrates 64 and72 and thus affixes the absorbent particulate polymer material 66 and 74to the substrates 64 and 72. Thus, in accordance with certainembodiments, the thermoplastic adhesive material 68 and 76 immobilizesthe absorbent particulate polymer material 66 and 74 when wet. Somethermoplastic adhesive materials will also penetrate into both theabsorbent particulate polymer material 66 and 74 and the substrates 64and 72, thus providing for further immobilization and affixation. Ofcourse, while the thermoplastic adhesive materials disclosed hereinprovide a much improved wet immobilization (i.e., immobilization ofabsorbent material when the article is wet or at least partiallyloaded), these thermoplastic adhesive materials may also provide a verygood immobilization of absorbent material when the absorbent core 14 isdry. The thermoplastic adhesive material 68 and 76 may also be referredto as a hot melt adhesive.

In accordance with certain embodiments, the thermoplastic adhesivematerial 68 and 76 may comprise, in its entirety, a single thermoplasticpolymer or a blend of thermoplastic polymers, having a softening point,as determined by the ASTM Method D-36-95 “Ring and Ball”, in the rangebetween 50° C. and 300° C., or alternatively the thermoplastic adhesivematerial may be a hot melt adhesive comprising at least onethermoplastic polymer in combination with other thermoplastic diluentssuch as tackifying resins, plasticizers and additives such asantioxidants. In certain embodiments, the thermoplastic polymer may havea molecular weight (Mw) of more than 10,000 and a glass transitiontemperature (Tg) usually below room temperature or −6° C.>Tg<16° C. Incertain embodiments, typical concentrations of the polymer in a hot meltare in the range of about 20 to about 40% by weight. In certainembodiments, thermoplastic polymers may be water insensitive. Exemplarypolymers are (styrenic) block copolymers including A-B-A triblockstructures, A-B diblock structures and (A-B)n radial block copolymerstructures wherein the A blocks are non-elastomeric polymer blocks,typically comprising polystyrene, and the B blocks are unsaturatedconjugated diene or (partly) hydrogenated versions of such. The B blockis typically isoprene, butadiene, ethylene/butylene (hydrogenatedbutadiene), ethylene/propylene (hydrogenated isoprene), and mixturesthereof.

Other suitable thermoplastic polymers that may be employed aremetallocene polyolefins, which are ethylene polymers prepared usingsingle-site or metallocene catalysts. Therein, at least one comonomercan be polymerized with ethylene to make a copolymer, terpolymer orhigher order polymer. Also applicable are amorphous polyolefins oramorphous polyalphaolefins (APAO) which are homopolymers, copolymers orterpolymers of C2 to C8 alpha olefins.

In exemplary embodiments, the tackifying resin may have a Mw below 5,000and a Tg usually above room temperature, typical concentrations of theresin in a hot melt are in the range of about 30 to about 60%, and theplasticizer has a low Mw of typically less than 1,000 and a Tg belowroom temperature, with a typical concentration of about 0 to about 15%.

In certain embodiments, the thermoplastic adhesive material 68 and 76 ispresent in the form of fibers. In some embodiments, the fibers may havean average thickness of about 1 to about 50 micrometers or about 1 toabout 35 micrometers and an average length of about 5 mm to about 50 mmor about 5 mm to about 30 mm. To improve the adhesion of thethermoplastic adhesive material 68 and 76 to the substrates 64 and 72 orto any other layer, in particular any other nonwoven layer, such layersmay be pre-treated with an auxiliary adhesive.

The absorbent core 14 may also comprise an auxiliary adhesive which isnot illustrated in the figures. The auxiliary adhesive may be depositedon the first and second substrates 64 and 72 of the respective first andsecond absorbent layers 60 and 62 before application of the absorbentparticulate polymer material 66 and 74 for enhancing adhesion of theabsorbent particulate polymer materials 66 and 74 and the thermoplasticadhesive material 68 and 76 to the respective substrates 64 and 72. Theauxiliary glue may also aid in immobilizing the absorbent particulatepolymer material 66 and 74 and may comprise the same thermoplasticadhesive material as described hereinabove or may also comprise otheradhesives including but not limited to sprayable hot melt adhesives,such as H.B. Fuller Co. (St. Paul, Minn.) Product No. HL-1620-B. Theauxiliary glue may be applied to the substrates 64 and 72 in variousways. For example, in some embodiments, the auxiliary glue may beapplied in about 0.5 to about 1 mm wide slots spaced about 0.5 to about2 mm apart.

The cover layer 70 shown in FIG. 4 may include the same material as thesubstrates 64 and 72, or may include a different material. In certainembodiments, the materials of the cover layer 70 are the nonwovenmaterials, such as the materials described above as useful for thesubstrates 64 and 72.

A printing system 130 for making an absorbent core 14 is shown in FIG. 9and may include a first printing unit 132 for forming the firstabsorbent layer 60 of the absorbent core 14 and a second printing unit134 for forming the second absorbent layer 62 of the absorbent core 14.

The first printing unit 132 may include a first auxiliary adhesiveapplicator 136 for applying an auxiliary adhesive to the substrate 64,which may be a nonwoven web, a first rotatable support roll 140 forreceiving the substrate 64, a hopper 142 for holding absorbentparticulate polymer material 66, a printing roll 144 for transferringthe absorbent particulate polymer material 66 to the substrate 64, and athermoplastic adhesive material applicator 146 for applying thethermoplastic adhesive material 68 to the substrate 64 and the absorbentparticulate polymer 66 material thereon.

The second printing unit 134 may include a second auxiliary adhesiveapplicator 148 for applying an auxiliary adhesive to the secondsubstrate 72, a second rotatable support roll 152 for receiving thesecond substrate 72, a second hopper 154 for holding the absorbentparticulate polymer material 74, a second printing roll 156 fortransferring the absorbent particulate polymer material 74 from thehopper 154 to the second substrate 72, and a second thermoplasticadhesive material applicator 158 for applying the thermoplastic adhesivematerial 76 to the second substrate 72 and the absorbent particulatepolymer material 74 thereon.

The printing system 130 also includes a guide roller 160 for guiding theformed absorbent core from a nip 162 between the first and secondrotatable support rolls 140 and 152.

The first and second auxiliary applicators 136 and 148 and the first andsecond thermoplastic adhesive material applicators 146 and 158 may be anozzle system which can provide a relatively thin but wide curtain ofthermoplastic adhesive material.

Turning to FIG. 10, portions of the first hopper 142, first support roll140, and first printing roll 144 are illustrated. As also shown in FIG.13, the first rotatable support roll 140, which has the same structureas the second rotatable support roll 152, comprises a rotatable drum 164and a peripheral vented support grid 166 for receiving the firstsubstrate 64.

As also shown in FIG. 11, the first printing roll 144, which has thesame structure as the second printing roll 156, comprises a rotatabledrum 168 and a plurality of absorbent particulate polymer materialreservoirs 170 in a peripheral surface 172 of the drum 168. Thereservoirs 170, such as shown in FIG. 12, may have a variety of shapes,including cylindrical, conical, or any other shape. The reservoirs 170may lead to an air passage 174 in the drum 168 and include a ventedcover 176 for holding adhesive particulate polymer material 66 in thereservoir and preventing the adhesive particulate polymer material 66from falling or being pulled into the air passage 174.

In operation, the printing system 130 receives the first and secondsubstrate 64 and 72 into the first and second printing units 132 and134, respectively, the first substrate 64 is drawn by the rotating firstsupport roll 140 past the first auxiliary adhesive applicator 136 whichapplies the first auxiliary adhesive to the first substrate 64 in apattern such as described hereinabove. A vacuum (not shown) within thefirst support roll 140 draws the first substrate 64 against the verticalsupport grid 166 and holds the first substrate 64 against the firstsupport roll 140. This presents an uneven surface on the first substrate64. Due to gravity, or by using the vacuum means, the substrate 64 willfollow the contours of the uneven surface and thereby the substrate 64will assume a mountain and valley shape. The absorbent particulatepolymer material 66 may accumulate in the valleys presented by thesubstrate 64. The first support roll 140 then carries the firstsubstrate 64 past the rotating first printing roll 144 which transfersthe absorbent particulate polymer material 66 from the first hopper 142to the first substrate 64 in the grid pattern 92 such as shown in FIGS.5 and 6. A vacuum (not shown) in the first printing roll 144 may holdthe absorbent particulate polymer material 66 in the reservoirs 170until time to deliver the absorbent particulate polymer material 66 tothe first substrate 64. The vacuum may then be released or air flowthrough the air passages 174 may be reversed to eject the absorbentparticulate polymer material 66 from the reservoirs and onto the firstsubstrate 64. The absorbent particulate polymer material 66 mayaccumulate in the valleys presented by the substrate 64. The supportroll 140 then carries the printed first substrate 64 past thethermoplastic adhesive material applicator 136 which applies thethermoplastic adhesive material 68 to cover the absorbent particulatepolymer material 66 on the first substrate 64.

Hence, the uneven surface of the vented support grid 166 of the supportrolls 140 and 152 determines the distribution of absorbent particulatepolymeric material 66 and 74 throughout the absorbent core 14 andlikewise determines the pattern of junction areas 96.

Meanwhile, the second rotatable support roll draws the second substrate72 past the second auxiliary adhesive applicator 148 which applies anauxiliary adhesive to the second substrate 72 in a pattern such as isdescribed hereinabove. The second rotatable support roll 152 thencarries the second substrate 72 past the second printing roll 156 whichtransfers the absorbent particulate polymer material 74 from the secondhopper 154 to the second substrate 72 and deposits the absorbentparticulate polymer material 74 in the grid pattern 92 on the secondsubstrate 72 in the same manner as described with regard to the firstprinting unit 132 above. The second thermoplastic adhesive materialapplicator 158 then applies the thermoplastic adhesive material 76 tocover the absorbent particulate polymer material 74 on the secondsubstrate 72. The printed first and second substrates 64 and 72 thenpass through the nip 162 between the first and second support rolls 140and 152 for compressing the first absorbent layer 60 and secondabsorbent layer 62 together to form the absorbent core 14.

In some configurations, a cover layer 70 may be placed upon thesubstrates 64 and 72, the absorbent particulate polymer material 66 and74, and the thermoplastic adhesive material 68 and 76. In anotherembodiment, the cover layer 70 and the respective substrate 64 and 72may be provided from a unitary sheet of material. The placing of thecover layer 70 onto the respective substrate 64 and 72 may then involvethe folding of the unitary piece of material.

It is to be appreciated that various embodiments of diapers can bemanufactured according the methods disclosed herein, such as forexample, the absorbent articles disclosed in U.S. Patent Publication No.2008/031621A1, which is hereby incorporated by reference herein.

Although much of the present discussion is presented in the context ofabsorbent articles in form of diapers, it is to be appreciated thatabsorbent articles, such as sanitary napkins can also be assembledaccording the methods and apparatuses disclosed herein. Absorbentarticles, such as sanitary napkins may be designed to be worn in closeproximity to the crotch of the wearer. Such absorbent articles need toprovide for fluid acquisition and retention and may look aestheticallypleasing, as well as be comfortable to wear. Examples of sanitarynapkins are provided in U.S. Patent Publication Nos. 2010/0036339;2010/0036347; and 2010/0036349, the disclosures of which are hereinincorporated by reference. In use, sanitary napkins are stressed by avariety of fluid handling demands. For instance, the central portion ofthe pad may be assaulted with fluid flow that may either be a trickle ora gush of fluid such as menstrual fluid. If the wearer is lying down onher front or back, fluid may have a tendency to run off of the front endor rear end of the absorbent article. Typical absorbent articles areapproximately the same width as the crotch of the wearer, which can besomewhat narrow. Thus, there is potential for fluid to run off the sidesof the absorbent article and soil the wings of the absorbent article, ifpresent, or soil the wearer's undergarment and/or clothing.

A woman's crotch region can comprise many different types of tissues.For instance, the pubic area, labia majora, inner thigh, and anus caneach have a different skin texture. Sanitary napkins commonly cover thelabia, portions of the crotch forward of the labia, portions of thecrotch rearward of the labia, and portions of the crotch laterallyadjacent the labia. As a woman wearing a sanitary napkin moves, portionsof the sanitary napkin can rub up against nearby body surfaces. Giventhe complex geometry of a woman's crotch region and the dynamic geometryof a woman's crotch as she moves, different portions of the woman'scrotch are exposed to different rubbing forces and the friction betweenthe sanitary napkin and wearer's crotch can vary depending on thelocation.

The moisture and chemical environments of a woman's crotch can also varyas a function of location. For instance, the labia majora may be exposedto menses and/or urine. The medial portion of the woman's pubic area maybe exposed to perspiration. Portions adjacent the medial area may besubjected to more moisture due to the lack of hair and the tendency fora woman's panty to closely conform to the juncture of the inner thighand the crotch and pubic area. The area near the anus may be exposed tomore perspiration and anal leakage than areas further away from theanus.

Given the variety of fluid handling demands placed on different portionsof an absorbent article, such as a sanitary napkin, the differentphysical interactions between portions of an absorbent article andportions of a wearer's body, and different moisture and chemicalenvironments of different portions of a wearer's crotch region, there iscontinuing and unaddressed need for absorbent articles havingaesthetically appealing, are comfortable to wear, but do not compromisethe performance of the absorbent article. Sanitary napkins made with theembossing process described herein provide an aesthetically appealingsurface to the body facing side of the article while not compromisingthe performance of the acquisition layer and maintaining the comfort ofthe article during wearing.

As previously mentioned, the apparatuses and methods according to thepresent disclosure may be utilized to assemble various components ofabsorbent articles. For example, FIG. 14 shows a schematic view of aconverting apparatus 300 adapted to manufacture diapers 10 havingembossed topsheets 18. The method of operation of the convertingapparatus 300 may described with reference to the various components ofdiapers 10 described above and shown in FIGS. 1-8. As described in moredetail below, the converting apparatus 300 shown in FIG. 14 operates toadvance a continuous topsheet web 18 in a machine direction. A liquidacquisition layer 50 and an absorbent core 14 are combined with theadvancing topsheet web 18. The combined continuous topsheet web 18,liquid acquisition layer 50, and absorbent core 14 are then advancedthrough the embossing apparatus 340 to emboss a pattern in thecontinuous topsheet web 18.

As shown in FIG. 14, a continuous topsheet web 18 having a first surface302 and an opposing second surface 304 is combined with a liquidacquisition system or layer 50. More particularly, the topsheet web 18is advanced in a machine direction MD to a nip 306 defined between acarrier apparatus 308 and roll 310, where the topsheet web 18 and liquidacquisition layer 50 are combined. Before entering the nip 306, adhesive312 may be applied to the second surface 304 of the topsheet web 18.

It is to be appreciated that the liquid acquisition layer 50 may beformed in various ways before being combined with the topsheet web 18.As discussed above, the liquid acquisition layer 50 may include one ormore layers of material. For example, as shown in FIG. 14, the liquidacquisition layer 50 has a first surface 324 and an opposing secondsurface 326 and may include a first acquisition layer 52 and a secondacquisition layer 54, wherein adhesive 314 is applied to the firstacquisition layer 52 before being combined with the second acquisitionlayer 54. The liquid acquisition layer 50 may also advance through a nip316 between rolls 318, 320 before advancing to the carrier apparatus306. As shown in FIG. 14, the acquisition layer 50 may be cut intodiscrete lengths by a knife roll 322 on the carrier apparatus 308 beforebeing combined with the topsheet web 18.

The carrier apparatus 308 and the knife roll 322 may utilize a cut andslip technique to space sequential discrete lengths of the acquisitionlayer 50 about the carrier apparatus 308. A cut and slip technique is anoperation for achieving spacing between discrete components. An exampleoperation for achieving spacing between discrete components is disclosedin U.S. Pat. No. 5,702,551, which is incorporated by reference herein.Other types of operations and equipment that may be used to cut andspace discrete lengths of components are disclosed in U.S. Pat. Nos.6,620,276; 6,811,019; and 7,587,966, which are incorporated by referenceherein in their entireties. The discrete lengths of acquisition layer 50are then combined with the topsheet web 18 at nip 306. In particular,the first surface 324 of the acquisition layer 50 may be adhered to thesecond surface 304 of the topsheet web 18 at nip 306. Although theacquisition layer 50 is shown in FIG. 14 as being cut into discretelengths before being combined with the topsheet web 18, it is to beappreciated that in some embodiments a continuous length of acquisitionlayer 50 may be combined with the topsheet web 18.

From the nip 306, the combined topsheet web 18 and liquid acquisitionlayer 50 advance in the machine direction MD to a nip 328 definedbetween a carrier apparatus 330 and roll 332, where the topsheet web 18and acquisition layer are combined with an absorbent core 14. Beforeentering the nip 328, adhesive 333 may be applied to the second surface304 of the acquisition layer 50 and/or topsheet web 18.

It is to be appreciated that the absorbent core 14 may be formed invarious ways before being combined with the topsheet web 18 andacquisition layer 50. For example, as shown in FIG. 14, the absorbentcore 14 has a first surface 334 and an opposing second surface 336 andmay be formed in accordance with the process description provided abovewith reference to FIGS. 9-13. As such, the absorbent core may includevarious components discussed above with reference to FIGS. 1-8, such asa first absorbent layer 60 and a second absorbent layer 62, wherein thefirst absorbent layer 60 of the absorbent core 14 may include asubstrate 64, an absorbent particular polymer material 66 on thesubstrate 64, and a thermoplastic composition 68 on the absorbentparticulate polymer material 66. And the second absorbent layer 62 ofthe absorbent core 14 may include a substrate 72, an absorbentparticulate polymer material 74 on the second substrate 72, and athermoplastic composition 66 on the absorbent particulate polymermaterial 74. As such, with reference to FIGS. 2 and 14, the substrate 72may define the first surface 334 of the absorbent core 14, and thesubstrate 64 may define the second surface 336 of the absorbent core 14.As shown in FIG. 14, the absorbent core 14 may also be cut into discretelengths by a knife roll 338 on the carrier apparatus 330 before beingcombined with the acquisition layer 50 and topsheet web 18.

The carrier apparatus 330 and the knife roll 338 may utilize a cut andslip technique to space sequential discrete lengths of the absorbentcore 14 about the carrier apparatus 330. A cut and slip technique is anoperation for achieving spacing between discrete components. An exampleoperation for achieving spacing between discrete components is disclosedin U.S. Pat. No. 5,702,551, which is incorporated by reference herein.Other types of operations and equipment that may be used to cut andspace discrete lengths of components are disclosed in U.S. Pat. Nos.6,620,276; 6,811,019; and 7,587,966, which are incorporated by referenceherein in their entireties. The discrete lengths of absorbent core 14are then combined the acquisition layer 50 and topsheet web 18 at nip328. In particular, the first surface 334 of the absorbent core 14 maybe adhered to the second surface 326 of the acquisition layer 50 at nip328. Although the absorbent core 14 is shown in FIG. 14 as being cutinto discrete lengths before being combined with the acquisition layer50 and topsheet web 18, it is to be appreciated that in some embodimentsa continuous length of absorbent core 14 may be combined with theacquisition layer 50 and topsheet web 18.

From the nip 328, the combined topsheet web 18, acquisition layer 50,and absorbent core 14 advance in the machine direction MD to anembossing apparatus 340, where a pattern is embossed into the topsheetweb 18. The embossing apparatus may include an embossing nip 342 definedbetween a patterned embossing roll 344 and an anvil roll 346. As shownin FIG. 14, the combined topsheet web 18, acquisition layer 50, andabsorbent core 14 advance in the machine direction MD through theembossing nip 342 such that the outer surface of the patterned embossingroll 344 engages the first surface 302 of the topsheet web and the outersurface of the anvil roll engages the second surface 336 of theabsorbent core 14. The topsheet web 18, acquisition layer 50, andabsorbent core 14 are compressed while advancing through the embossingnip 342, and the embossing roll 344 embosses a pattern of embossmentsinto the topsheet web 18. It is to be appreciated that the topsheet web18, acquisition layer 50, and absorbent core 14 can be combined withother absorbent article components as described above in an assemblyprocess, such as for example, a backsheet, fastening components, legcuffs, and elasticated features.

It is to be appreciated that the embossing apparatus can be configuredin various ways. In some embodiments, one or both the patternedembossing roll 344 and the anvil roll 346 may be heated. For example, insome embodiments, the patterned embossing roll 344 is heated to asurface temperature of 160° C. In some embodiments, the patternedembossing roll 344 and the anvil roll 346 have the same diameters androtate at the same speeds. It should also be appreciated that thepatterned embossing roll 344 and the anvil roll 346 may be made ofvarious types of materials, wherein the patterned embossing roll 344 andthe anvil roll 346 are made from the same or different types ofmaterials. For example, in some embodiments, both the patternedembossing roll 344 and the anvil roll 346 are made from D2 tool steel.In addition, the embossing apparatus may be configured such that thepatterned embossing roll includes an embossing pattern on the outersurface and the anvil roll includes a smooth outer surface.

It is to be appreciated that the embossing apparatus can be configuredto emboss various types of patterns in the topsheet 18. As such, theouter surface of the patterned embossing roll 344 can be configured withvarious types of embossing elements (or protrusions) in the form of nubsand/or ridges that compress and/or deform the topsheet 18 and othercomponents passing through the embossing nip 342.

As used herein, the term “discrete” with reference to embossing elementsmeans that the embossing element (which may be interchangeably refereedto herein as an embossing protrusion or protuberance) is not contiguouswith another embossing element, but rather is separated from all otherembossing elements by some distance. Although discrete embossingelements can be any size or shape, in some embodiments, the embossingelements are circular or oval in cross-section at their distal end (i.e.the end farthest away from the surface from which the embossing elementextends). If generally circular in cross-section, the discrete embossingelements may have a diameter at their distal end of less than about 15mm, less than about 7.5 mm, less than about 5.0 mm, less than about 3.0mm, less than about 1.0 mm, between about 1.0 mm and about 15 mm, or anynumber within this range. In embodiments wherein the discrete embossingelements are non-circular, the discrete embossing elements may have amajor length dimension (i.e. the longest dimension at the distal endparallel to the surface from which the embossing element extends) and aminor length dimension (i.e. the shortest dimension at the distal endparallel to the surface from which the embossing element extends). Thedimensions set forth above with regard to the diameter of the distal endof generally circular discrete embossing elements are applicable to themajor length at the distal end of non-circular discrete embossingelements. Further, in such cases, in order to not be considered linear,the discrete embossing elements will have a ratio of the major length tothe minor length dimension of less than about 3.5:1, less than about3:1, less than about 2.5:1, between about 3.5:1 and about 1:1, or anyratio within the range.

Embossing elements act on a substrate to create correspondingly shapedembossments in the substrate. As used herein, the term “discrete” withreference to embossments means that the embossment (which may beinterchangeably referred to herein as an indented region) is notcontiguous with another embossment, but rather is separated from allother embossments by some distance. As shown in FIGS. 15 and 16, forexample, discrete embossments (indented regions) 352 are separated fromeach other by unembossed regions (unindented regions) 354.

In some embodiments, the embossing elements may include an averageheight of about 7000 μm. Other embodiments may have embossing elementshaving heights greater than about 3000 μm, for example, greater thanabout 2000 μm, greater than about 1000 μm or any individual numberwithin this range.

As used herein, the term “continuous” refers to an embossing patternincluding an embossing element that extends continuously along at leastone path without a break or interruption. That is, one can trace alongthe entirety of the continuous embossing pattern without ever having tocross a break or interruption in the pattern.

As used herein, the term “linear” as it refers to embossing elementsmeans that embossing elements that have a length and a width, whereinthe ratio of the length to the width is as least about 4:1, at leastabout 5:1 or at least about 10:1. Further, a linear element could becontinuous, as described herein. Thus, the length would generallycorrespond to the length of the centerline of the outline of the shapeformed by the linear embossing elements as opposed to a distancebisecting or otherwise cutting across a portion of the shape. In certainembodiments, it may be desirable that the width of the linear embossingelement be less than about 15.0 mm, less than about 7.5 mm, less thanabout 5.0 mm, less than about 2.5 mm, less than about 1.0 mm, betweenabout 1.0 mm and about 15.0 mm, or any number within this range.

The term linear does not require that the embossing element be of anyparticular shape, other than set forth herein, and it is contemplatedthat such linear embossing elements can include generally straight linesor curved lines or combinations thereof. In addition, a “linear” elementneed not be uniform in width and/or height. (For the purposes of thisapplication, the width measurement used to determine the length to widthratio is the widest (or largest width measurement) taken along thelength of the embossing element.) Further, the linear embossing elementscan form patterns and/or shapes that repeat or do not repeat. Thus, thepattern, if any, formed by the linear embossing elements can be regularor non-regular, as desired.

The pattern could include linear embossing elements in addition to thediscrete and/or non-discrete embossing elements. More specifically, thelinear embossing elements may have a length L to width W ratio that isas least about 4:1, at least about 5:1 or at least about 10:1. Althoughthe length L and width W of the linear embossing elements can be anysuitable number, in certain embodiments, it may be desirable that thewidth W of the linear embossing element be less than about 15 mm, lessthan about 7.5 mm, less than about 5.0 mm, less than about 2.5 mm, lessthan about 1.0 mm, between about 1.0 mm and about 15 mm, or any numberwithin this range.

As noted above, the term linear does not require that the embossingelement be of any particular shape and it is contemplated that suchlinear embossing elements can include generally straight lines or curvedlines or combinations thereof. Also, as stated above, linear elementneed not be uniform in width W. A few non-limiting examples of variousdifferent possible linear embossing elements with non-uniform widths arealso possible.

The linear embossing elements can form patterns and/or shapes thatrepeat or do not repeat. The linear embossing elements may be shapedsuch that they include an enclosed or at least partially enclosedregion. It may also be desirable to design the discrete embossingelements such that the total area of the area of the distal ends of allof the discrete embossing elements is less than about 25%, less thanabout 20%, less than about 15%, less than about 13%, less than about12.5%, less than about 10%, less than about 5% or even less than about2.5% of the total planar projected area defined by the smallestrectangle that can surround the combined embossing pattern for a singleabsorbent article.

The combined embossing pattern can include a repeating pattern ofembossing elements (e.g. linear and/or discrete). The combined embossingpattern can be repeated from absorbent article to absorbent article on aproduction line.

To calculate a total area value for the distal ends of any particulartype of embossing element or elements the individual area of each of thedistal ends, is measured. The total area value is the sum of theindividual areas measured. One suitable method for obtaining the areameasurements is by using computer aided drafting software, such asAUTOCAD 2004.

It may be desirable that the total area of the distal ends of theembossing element (e.g. linear and/or discrete) in any combinedembossing pattern is a certain area or less. For example, it may bedesirable that the total area of the distal ends of the linear embossingelements is less than about 10 cm2, less than about 7.5 cm2, less thanabout 5.0 cm2, less than about 3.0 cm2 or less than about 2.5 cm2.

As shown in FIG. 15, the resulting embossed topsheet 18 may haveembossments (indentations) 352 with various average embossment depths356. For example, in some embodiments, the average embossment depth 356may be at least about 650 μm. Other embodiments may have embossments 352with embossment depths 356 greater than 1000 μm, greater than about 1250μm, greater than about 1450 μm, at least about 1550 μm, at least about1800 μm, at least about 2000 μm, at least about 3000 μm, at least about4000 μm, between about 650 μm and about 4000 μm or any individual numberwithin this range. The average embossment depth may be measured by theEmbossment Depth Test Method using a GFM MikroCAD optical profilerinstrument, as described in the nonprovisional U.S. patent applicationentitled, “Disposable Absorbent Articles with an Embossed Topsheet,”filed on Mar. 14, 2011, and identified by attorney docket number 12030,which is incorporated by reference herein.

With continued reference to FIG. 15, the embossing apparatus may also beconfigured to operate with various different nip pressures andembossment depths that may result in compression of different componentswhile passing through the embossing nip 342. Depending on the absorbentcore construction, it may also be desirable to avoid tearing orotherwise rupturing the substrate 72 and/or substrate 64 of theabsorbent core 14 while passing through the embossing nip 342. Theembossing apparatus may also be configured to avoid tearing or otherwiserupturing the topsheet 18.

In some embodiments as the topsheet web 18, acquisition layer 50, andabsorbent core 14 advance through the embossing nip 342, the topsheet 18and the acquisition layer 50 are deformed by the embossing elements 350on the patterned embossing roll 344, while the absorbent core 14 is notdeformed by the embossing elements 350. For example, as shown in FIG.15, as the topsheet web 18, acquisition layer 50, and absorbent core 14advance through the embossing nip 342, the topsheet 18, firstacquisition layer 52, and second acquisition layer 54 are deformed bythe embossing elements 350 on the patterned embossing roll 344, whilethe absorbent core 14 is not deformed by the embossing elements. In someembodiments, as the topsheet web 18, acquisition layer 50, and absorbentcore 14 advance through the embossing nip 342, the topsheet 18 and thefirst acquisition layer 52 are deformed by the embossing pattern on thepatterned embossing roll 344, while the absorbent core 14 and the secondacquisition layer 54 are not deformed by the embossing pattern. In stillother embodiments, the topsheet web 18, acquisition layer 50, andabsorbent core 14 are all deformed by the embossing pattern whileadvancing through the embossing nip 342.

As previously mentioned, the embossing apparatus may be configured toavoid tearing or otherwise rupturing components passing through theembossing nip 342. In some embodiments, the embossing apparatus may beconfigured to avoid the exerting pressures on the components that mayresult in thermally bonding fibers of various components, such as forexample, fibers of a nonwoven topsheet web 18. It should also beappreciated that various components may not be permanently deformedand/or compressed after passing through the embossing nip 342. Forexample, as shown in FIG. 15, the topsheet 18, first acquisition layer52, and second acquisition layer are all deformed and/or compressedwhile passing through the embossing nip 342. However, the degree ofcompression in the topsheet 18 and first acquisition layer 52 islessened after advancing from the embossing nip 342, while thecompression of the second acquisition layer 54 is substantially entirelyremoved.

In some embodiments after advancing from the embossing nip 342, such asshown in FIGS. 15 and 16, the topsheet 18 includes discrete embossments(discrete indentations) 352 having a depth 356. The depth 356 of theembossments 352 in the topsheet 18 may be greater than the caliper 357of the topsheet 18. The first acquisition layer 52 may also includeembossments 358 having a depth 360. The depth 360 of the embossments 358in the first acquisition layer 52 may be the same as or less than thedepth 356 of the embossments 352 in the topsheet 18. In embodimentswhere the topsheet 18 and liquid acquisition layer 50 pass through theembossing nip 342 at the same time, the embossments 358 in the firstacquisition layer 52 may have corresponding locations, shapes, and/orsizes with the embossments 352 in the topsheet 18.

It is to be appreciated that combined embossed topsheet 18, liquidacquisition layer 50, and absorbent core 14 may be combined with othercomponents, such as for example, backsheet webs, leg cuffs, ears, side,panels, leg cuffs, and/or fastening elements, to produce an absorbentarticle such as described above.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A process for assembling disposable absorbent articles, eachabsorbent article comprising a chassis having a first waist regionlongitudinally opposed to a second waist region, and having alongitudinal axis and a lateral axis, the chassis comprising: atopsheet, a backsheet, and a liquid acquisition layer and asubstantially cellulose free absorbent core disposed between thetopsheet and the backsheet, the process comprising the steps of:advancing a continuous topsheet web having a first surface and anopposing second surface in a machine direction; combining a liquidacquisition layer with the continuous topsheet web, wherein the liquidacquisition layer includes a first surface and an opposing secondsurface, and wherein the first surface of the liquid acquisition layeris positioned in a facing relationship with the second surface of thecontinuous topsheet web; combining an absorbent core with the liquidacquisition layer, wherein the absorbent core includes a first surfaceand an opposing second surface, and wherein the first surface of theabsorbent core is positioned in a facing relationship with the secondsurface of the liquid acquisition layer; providing an embossing nipbetween a rotating patterned embossing roll and a rotating anvil roll;and embossing a pattern in the continuous topsheet web by advancing thecombined continuous topsheet web, liquid acquisition layer, andabsorbent core through the embossing nip, wherein the rotating patternedembossing roll contacts the first surface of the continuous topsheetweb, and wherein the rotating anvil roll contacts the second surface ofthe absorbent core.
 2. The process of claim 1, wherein the step ofcombining a liquid acquisition layer with the continuous topsheet webfurther comprises the operation of applying adhesive to the secondsurface of the continuous topsheet web.
 3. The process of claim 1,wherein the step of combining an absorbent core with the liquidacquisition layer further comprises the operation of applying adhesiveto the second surface of the liquid acquisition layer.
 4. The process ofclaim 1, wherein the liquid acquisition layer comprises an upperacquisition layer and a lower acquisition layer, wherein the upperacquisition layer defines the first surface of the liquid acquisitionlayer and the lower acquisition layer defines the second surface of theliquid acquisition layer.
 5. The process of claim 1, further comprisingthe step of: combining a continuous backsheet web with the combinedcontinuous topsheet web, liquid acquisition layer, and absorbent coreexit the embossing nip.
 6. The process of claim 1, further comprisingthe step of heating the patterned embossing roll.
 7. The process ofclaim 1, further comprising the step of deforming the continuoustopsheet web and liquid acquisition layer without embossing theabsorbent core while advancing the combined continuous topsheet web,liquid acquisition layer, and absorbent core through the embossing nip.8. The process of claim 7, wherein the liquid acquisition layercomprises an upper acquisition layer and a lower acquisition layer, andwherein the step of embossing further comprises embossing the upperacquisition layer without deforming the lower acquisition layer.
 9. Aprocess for assembling disposable absorbent articles, each absorbentarticle comprising a chassis having a first waist region longitudinallyopposed to a second waist region, and having a longitudinal axis and alateral axis, the chassis comprising: a topsheet, a backsheet, and aliquid acquisition layer and a substantially cellulose free absorbentcore disposed between the topsheet and the backsheet, the processcomprising the steps of: advancing a continuous topsheet web having afirst surface and an opposing second surface in a machine direction;combining a liquid acquisition layer with the continuous topsheet web,wherein the liquid acquisition layer includes a first surface and anopposing second surface, and wherein the first surface of the liquidacquisition layer is positioned in a facing relationship with the secondsurface of the continuous topsheet web; combining an absorbent core withthe liquid acquisition layer, wherein the absorbent core includes afirst surface and an opposing second surface, and wherein the firstsurface of the absorbent core is positioned in a facing relationshipwith the second surface of the liquid acquisition layer; providing anembossing nip between a rotating embossing roll and a rotating anvilroll, the embossing roll comprising an embossing element; and creatingindented regions in the continuous topsheet web by advancing thecombined continuous topsheet web, liquid acquisition layer, andabsorbent core through the embossing nip, wherein the embossing elementcontacts the first surface of the continuous topsheet web, and whereinthe rotating anvil roll contacts the second surface of the absorbentcore.
 10. The process of claim 9, further comprising the step ofcreating indented regions in the continuous topsheet web and liquidacquisition layer without creating indented regions in the absorbentcore while advancing the combined continuous topsheet web, liquidacquisition layer, and absorbent core through the embossing nip.
 11. Theprocess of claim 10, wherein the liquid acquisition layer comprises anupper acquisition layer and a lower acquisition layer, and wherein thestep of creating indented regions further comprises creatingcorresponding indented regions in the upper acquisition layer withoutcreating indentated regions in the lower acquisition layer.
 12. Theprocess of claim 9, wherein the step of combining a liquid acquisitionlayer with the continuous topsheet web further comprises the operationof applying adhesive to the second surface of the continuous topsheetweb.
 13. The process of claim 9, wherein the step of combining anabsorbent core with the liquid acquisition layer further comprises theoperation of applying adhesive to the second surface of the liquidacquisition layer.
 14. The process of claim 9, wherein the liquidacquisition layer comprises an upper acquisition layer and a loweracquisition layer, wherein the upper acquisition layer defines the firstsurface of the liquid acquisition layer and the lower acquisition layerdefines the second surface of the liquid acquisition layer.
 15. Theprocess of claim 9, further comprising the step of: combining acontinuous backsheet web with the after the combined continuous topsheetweb, liquid acquisition layer, and absorbent core exit the embossingnip.
 16. The process of claim 9, further comprising the step of heatingthe embossing roll.